Zero turning radius mower

ABSTRACT

A zero turning radius mower has an internal combustion engine mounted transversely on a pair of longitudinal frame members behind an operator seat and a pair of rear drive wheels. The engine rotates a flywheel on a horizontal axis perpendicular to the longitudinal frame members. A gearbox is mounted to one of the longitudinal frame members, with a horizontal input shaft driven by the engine and a vertical output shaft engaging one or more rubber belts. The same rubber belts drive a pair hydrostatic transmissions for the pair of rear drive wheels and a plurality of rotary mower blades under a mower deck.

FIELD OF THE INVENTION

This invention relates to zero turning radius (“ZTR”) mowers having rearmounted engines and independently powered left and right drive wheelscontrolled with hydrostatic transmissions.

BACKGROUND OF THE INVENTION

Zero turning radius (“ZTR”) mowers have at least one independentlypowered drive wheel on each side of a frame. Hydrostatic transmissionstransmit power to each of the left and right drive wheels, either inforward or reverse. The pair of hydrostatic transmissions, or dualhydrostatic transmission, may be driven by an internal combustionengine. The independent rear drive wheels allow the ZTR mower to turn ona vertical turning axis. The vertical turning axis may be centrallylocated between the pair of hydrostatic transmissions.

ZTR mowers have frames with left and right longitudinal frame memberssupported on a forward end by front wheels and extending rearwardly tosupport an internal combustion engine. A mower deck may be suspendedbetween the front and rear wheels. A seated operator may use left andright control levers or other steering controls to control the pair ofhydrostatic transmissions driving the left and right rear drive wheels.

Internal combustion engines on ZTR mowers are mounted on the mower frameor platform behind the operator seat and rear wheels. Many ZTR mowershave internal combustion engines with vertical drive shafts. Pulleys onthe vertical drive shafts drive belts that transmit power from theengine to the pair of hydrostatic transmissions with vertical shafts,and transmit power from the engine to pulleys on vertical shafts of amower deck. Examples of ZTR mowers with vertical shaft engines includeU.S. Pat. No. 5,816,034 for “Belt Design for Mower,” U.S. Pat. No.6,952,913 for “Adjustable Belt Pulley System,” U.S. Pat. No. 7,596,934for “Lawn Mower with Belt Drive System,” U.S. Pat. No. 7,717,219 for“Unitary Rear Frame for Mounting Engine, Hydrostatic Transmission, andOther Components to Mower,” and U.S. Pat. No. 7,913,479 for “Two-PulleyBelt Tensioning Mechanism.”

Alternatively, some ZTR mowers have internal combustion engines,typically with higher horsepower, having horizontal drive shaftsoriented along the fore-aft axis of the mower. To transmit power from ahorizontal shaft engine to vertical shaft pulleys of the hydrostatictransmissions and mower deck, mule drives are typically used. Muledrives include one or more belts that are driven by a pulley on theengine's horizontal drive shaft, twisting the belt to engage pulleys onvertical shafts of the hydrostatic transmissions and mower deck.Examples of ZTR mowers with horizontal drive shafts and mule drivesinclude U.S. Pat. No. 5,865,020 for “Lawn Mower Having a Lower Center ofGravity,” U.S. Pat. No. 6,651,413 for “Multiple Belt Mule DriveApparatus and Systems/Vehicles Using Same,” U.S. Pat. No. 7,427,247 for“Mower Incorporating a Mule Drive,” and U.S. Pat. Nos. 7,665,284 and7,856,799 for “Belt Drive for Lawn Mowers.”

ZTR mowers with horizontal shaft engine are typically longer than ZTRmowers with vertical shaft engines, because the engines and mule drivesextend farther behind the operator seat. Horizontal drive shaft enginesand mule drives may extend rearwardly outside the ZTR mower's turningradius or turning circle, reducing the maneuverability of the ZTR mower,especially when mowing close to obstacles. A ZTR mower is needed with ahorizontal drive shaft engine, but without the engine or mule driveextending rearwardly outside the ZTR mower's turning radius or turningcircle. Additionally, mule drives require substantial distance and spacebetween the horizontal and vertical shafts in order to twist the belts.A ZTR mower is needed with a horizontal engine that does not require amule drive.

Gearboxes may be used to convert a horizontal shaft drive to a verticalshaft drive. However, conventional gearboxes have gaseous pressure thatbuilds up inside the gearbox as temperatures increase. In the past,spring-loaded vents have been used to vent gearboxes to atmosphere, withventing parts extending out through the gearbox wall. These ventspresent packaging issues, and may require cutting or modifying the mowerframe next to the gearbox wall where the vent is located. A ZTR mower isneeded with a gearbox vent having fewer parts and lower cost thanconventional spring-loaded gearbox vents, lower risk of damage duringassembly or operation, and reduced or eliminated packaging issues.

SUMMARY OF THE INVENTION

A zero turning radius mower includes an internal combustion enginehaving a flywheel rotating on a horizontal axis and connected to aninput shaft of a right angle gearbox. A pair of hydrostatictransmissions are driven by a belt engaged to an output shaft of thegearbox. A mower deck also is driven by the belt. The engine and gearboxare mounted to a frame within a turning circle having a vertical axisbetween the pair of hydrostatic transmissions and a perimeter at anouter edge of the pair of rear traction drive tires.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a ZTR mower according to a first embodiment ofthe invention.

FIG. 2 is a perspective view of the engine and drive train of a ZTRmower according to a first embodiment of the invention.

FIG. 3 is a cross section view of a gearbox with a gearbox vent on a ZTRmower according to a first embodiment of the invention.

FIG. 4 is a partially exploded perspective view of a gearbox with agearbox vent on a ZTR mower according to a first embodiment of theinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

In the embodiment shown in FIGS. 1-2, zero turning radius (“ZTR”) mower100 has a rear drive wheel 102, 104 on each side of the vehicle that ispowered to rotate independently of the other rear drive wheel. Theindependent rear drive wheels allow the ZTR mower to turn on verticalturning axis 106. The vertical turning axis may be centrally locatedbetween a pair of hydrostatic transmissions 108, 110 for the rear drivewheels. The hydrostatic transmissions may be compact integrated zeroturn transaxles. The ZTR mower may turn around on central turning axis106, in which radius 112 and perimeter 113 are defined by the rear drivewheels and tires.

In one embodiment, ZTR mower 100 may have frame 114 with left and rightlongitudinal frame members 116, 118 supported on a forward end by frontwheels 120, 122 and extending rearwardly past operator seat 165 and reardrive wheels 102, 104 where the longitudinal frame members terminate andconnect to rear cross member 134. Mower deck 124 may be suspended fromthe frame between the front and rear wheels. A seated operator may useleft and right control levers 126, 128 or other steering controls, tocontrol the pair of hydrostatic transmissions driving the left and rightrear drive wheels.

In one embodiment, internal combustion engine 130 may be mountedtransversely on the ZTR mower frame behind and rearwardly of operatorseat 165 and rear drive wheels 102, 104. The transversely mounted enginemay have flywheel 131 rotating on horizontal axis 129 oriented fromright to left across the frame of the ZTR mower, perpendicular to theleft and right longitudinal frame members. The transversely mountedengine may be mounted with engine mounts on longitudinal frame members116, 118 and one or more cross members 134.

In one embodiment, the transversely mounted engine, and left and rightlongitudinal frame members and cross members supporting the engine, arelocated inside or within the perimeter 113 of radius 112. This enablesthe ZTR mower to turn around and reverse direction while mowing close toobstacles.

In one embodiment, gearbox 136 may be mounted to the drive shaft orflywheel 131 and may convert the engine's horizontal rotational axis 129to a vertical rotational axis for common belt drive 138. The common beltdrive may power the rear drive wheels through the pair of hydrostatictransmissions 108, 110 and power the rotary cutting blades of the mowerdeck through jackshaft assembly 140. The gearbox may be a right anglegearbox mounted in bracket 142, which may be attached to the outside oflongitudinal frame member 116, but inside perimeter 113 of radius 112.

In one embodiment, as shown in FIG. 2, common belt drive 138 may includea pair of rubber V-belts 144, 146 driven by double pulley 148 secured tothe lower end of the gearbox's vertical output shaft 150. The same beltor pair of belts may engage pulleys 152, 154 on vertical shafts on eachof the hydrostatic transmissions, and pulley 156 on the vertical shaftof jackshaft assembly 140. Alternatively, the common belt drive mayinclude three rubber V-belts driven by three pulleys mounted to thelower end of the gearbox's vertical output shaft. The jackshaft assemblymay include a deck drive clutch that may be engaged and disengaged by anelectrical switch. Rubber belt 158 may connect the jackshaft assembly toone or more deck drive pulleys on vertical spindles that rotate aplurality of rotary cutting blades under the mower deck.

In one embodiment, as shown in FIG. 3, gearbox 136 may include spiralbevel gears 160, 162 on horizontal input shaft 164 and vertical outputshaft 150. The spiral bevel gears and shafts may be disposed at rightangles to each other, to change the transmitting direction from thegenerally horizontal axis of the engine drive shaft to the vertical axisof the common belt drive. The gearbox also may form an oil sump so thatthe shafts and gears may be adequately coated with lubricating oil whilethey rotate.

In one embodiment, coupler 166 may connect the engine flywheel 131 orhorizontal drive shaft to the gearbox's horizontal input shaft 164. Theinput shaft may be supported for rotation by bearings 168, 170, andseals that engage the cylindrical surface of the input shaft to preventleakage of oil or entry of contaminants. Spiral bevel gear 160 may besecured to the input shaft with nut 172. Vertical output shaft 150 mayextend through the top and bottom of the gearbox, and may be supportedfor rotation by upper and lower bearings 174, 176, and upper and lowerseals that engage and seal the cylindrical surface of the output shaft.Spiral bevel gear 162 may be secured to the gearbox's vertical outputshaft between the upper and lower bearings.

In one embodiment, gearbox 136 may include gearbox vent 175 throughvertical output shaft 150. The gearbox vent may be provided through thevertical output shaft to allow internal gearbox pressures to vent toatmosphere, and to prevent high internal pressures from causing seals inthe gearbox to burst or leak. The gearbox vent through the verticaloutput shaft also eliminates the need for a conventional spring-loadedvent, which requires space on the gearbox housing, adds costs and can bedamaged easily.

In one embodiment, gearbox vent 175 may include radial vent passage 178connected to an axial vent passage 180. The radial vent passage may be across drilled hole through the diameter of the vertical output shaft,and the axial vent passage may connect the radial vent hole with the topend 182 of the vertical output shaft. To enter radial vent passage 178,gaseous internal pressures in the gearbox may pass around upper bearing174. Radial vent passage 178 may be positioned above upper bearing 174,so that the upper bearing may protect and shield the vent passage fromdirect oil splash, oil migration and debris clogging. To exit axial ventpassage 180, the internal pressures must pass around bolt 184 whichsecures rotary cooling fan 190 to the vertical output shaft. An airpassage may be provided between the bolt threads and the internalthreads of axial vent passage 180. For example, bolt 184 may have flats186, 188 on its opposing sides that prevent the threads from sealing thejoint. Alternatively, instead of a flat-sided bolt, a banjo bolt may beused, having a cross drilled hole through its diameter and an axial holebetween the cross drilled hole and its threaded end.

In one embodiment, after leaving axial vent passage 180, the internalpressures may escape and vent to atmosphere through passage 208 in thecentral hub 196 of rotary cooling fan 190. Passage 208 may include aradial gap and an axial gap between the central hub and vertical outputshaft. As shown in FIG. 4, central hub 196 may have an oblong orrectangular opening that fits onto a pair of flats 192, 194 on the topend of the vertical output shaft, so the central hub may seat on thevertical output shaft's shoulders 202, 204. The radial gap may be a pairof slots 198, 200 that extend radially out from the central hub past thevertical output shaft's shoulders, forming air vents between the centralhub and vertical output shaft's outer circumference. The axial gap maybe between the central hub and the vertical output shaft's top end. Forexample, the axial gap may be provided by positioning washer 206 on thecentral hub between bolt 184 and the vertical output shaft's top end182.

In one embodiment, gearbox vent 175 may be configured to prevent oilfrom entering and clogging any of the vent passages. For example, thediameter of the vent passages may be sufficiently large to inhibitcapillary oil migration, and preferably the diameter of each ventpassage may be at least about 3 mm. Additionally, centrifugal forces ofthe spinning vertical output shaft may throw oil outward away from thevent passages.

Having described the preferred embodiment, it will become apparent thatvarious modifications can be made without departing from the scope ofthe invention as defined in the accompanying claims.

1. A zero turning radius mower, comprising: an internal combustion engine mounted transversely on a pair of longitudinal frame members behind an operator seat and a pair of rear drive wheels, the engine rotating a flywheel on a horizontal axis perpendicular to the longitudinal frame members; a gearbox mounted to one of the longitudinal frame members; the gearbox having a horizontal input shaft driven by the engine and a vertical output shaft engaging a rubber belt; the rubber belt driving a pair hydrostatic transmissions for the pair of rear drive wheels and driving a pulley rotating a plurality of rotary mower blades under a mower deck.
 2. The zero turning radius mower of claim 1 further comprising a central turning axis behind the operator seat and having a radius and perimeter defined by the rear drive wheels and tires; the internal combustion engine positioned inside the perimeter.
 3. The zero turning radius mower of claim 2 wherein the longitudinal frame members and the gearbox are positioned within the perimeter.
 4. The zero turning radius mower of claim 1 further comprising at least two belts driven by the vertical output shaft.
 5. The zero turning radius mower of claim 1 further comprising cooling fan on gearbox.
 6. A zero turning radius mower, comprising: a frame having left and right longitudinal frame members supported on a forward end by front wheels and extending rearwardly past an operator seat and a pair of rear drive wheels, the longitudinal frame members terminating and connecting to a rear cross member; a mower deck suspended from the frame between the front wheels and rear drive wheels and having a plurality of rotary cutting blades; left and right control levers that are pivotable to control the left and right rear drive wheels; and an internal combustion engine mounted transversely on the ZTR mower frame and supported by the longitudinal frame members and rear cross member behind and rearwardly of the operator seat and rear drive wheels; the engine connected to a right angle gearbox on one side of the longitudinal frame members; and a common belt drive transmitting power from the gearbox to a pair of hydrostatic transmissions for the pair of rear drive wheels and to the mower deck.
 7. The zero turning radius mower of claim 6, wherein the gearbox is mounted to a bracket extending outwardly from one of the longitudinal frame members.
 8. The zero turning radius mower of claim 6 wherein the common belt drive includes at least two belts.
 9. The zero turning radius mower of claim 6 wherein the transversely mounted engine and the gearbox are both within the perimeter of a circle having a center between the rear drive wheels and a radius at an outside edge of the rear drive wheels and tires.
 11. A zero turning radius mower, comprising: an internal combustion engine having a flywheel rotating on a horizontal axis and connected to an input shaft of a right angle gearbox; a pair of hydrostatic transmissions driven by a belt engaged to an output shaft of the gearbox and rotating a pair of rear traction drive tires; a mower deck driven by the belt; the engine and the gearbox mounted to a frame within a turning circle having a vertical axis between the pair of hydrostatic transmissions and a perimeter at an outer edge of the pair of rear traction drive tires.
 12. The zero turning radius mower of claim 11 further comprising at least two belts engaged to an output shaft of the gearbox and driving the pair of hydrostatic transmissions and the mower deck. 